Ultrasonic Welder Uses Novel Technology to Deliver High Repeatability
December 1, 2009 – 5:07 pm
A recently introduced servo-controlled ultrasonic welding system for medical applications from Dukane Corp.’s Ultrasonics Division is based on the company’s Melt Match technology, which delivers high repeatability, strong welds, simple validation calibration and low manufacturing cost compared to standard pneumatic welders.
The heart of the new ultrasonic welding system is Melt Match technology, a unique method that precisely controls the collapse speed profile during the weld. Collapsing too slowly may cause material degradation while collapsing too quickly may result in cold forming, according to Michael Johnston, national sales and marketing manager. Melt Match is unique because it precisely matches the collapse speed during the melt phase. As a result, the ultrasonic propagation penetrates deeper into the bond area and the affected heat zone is larger, resulting in superior bond strength. This contrasts to typical pneumatic welders that continue to travel during the hold phase, unlike a servo-controlled welder that can either stop and/or continue to collapse a specified distance and speed during the hold phase.
This high repeatability results in fewer rejects for manufacturers. In fact, testing shows that the average standard deviation for filter housing parts welded on a servo unit was 1.8% compared to 6.6% for those welded on a pneumatic machine.
The iQ servo-controlled welder also offers more consistent part height unlike pneumatic welders whose continuous travel during the hold phase may affect part height. The iQ servo welder “controls the entire process,” according to Johnston, and thus the collapse standard deviation of the iQ welder is three times better than that of a pneumatic machine.
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